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Retrofit

More efficiency, performance and safety

The refitting, extension or modernization of an existing machine is a step which is required for every machine at some point. Machine wear makes a refit necessary in order to ensure reliability and reduce downtime. It is also important in regard to ensuring competitiveness.

In comparison to investing in new machinery “retrofit” offers great advantages – this example of a refit of a roll-ex® is a case in point. By this example we show you several possible modernization measures which can be implemented on your machine – according to its current status. Please feel free to contact us!

1 HMI

Integration of a user panel with new components, for example:

  • Decentral PLC system
  • 9″ operator touch panel
  • Modern, user-friendly operating elements (switches, buttons)

Advantages: Easier operation, better visualization, increased work safety.

2 Breaker Plate

Retooling to 2-piece breaker plate

Advantages: Optimized flow, minimized use of pressure, easier cleaning.

3 Control Cabinet and Automatisation

Set-up of a power cabinet with new components. For example:

  • Main switch
  • Main contactor
  • Relays
  • Circuit breaker
  • Terminals
  • Fail-safe PLC system
  • Optional: Remote, DataLox and VisuGraph V2 (more about VisuGraph V2)
  • Exisiting frequency inverter are checked and re-installed

Advantages: Increased safety/reliability, technological advances (latest industrial standards), compliance to current safety standards. Improved possibilities for remote maintenance/support increase machine availability. Optimized interfaces for machine and process data.

4 Temperature Control Units

Inspection, maintenance or replacement of all sensor and actuating systems, for example:

  • Valves
  • Lamps
  • Regulators

Advantages: Powerful temperature control units using compact devices and improved energy efficiency.

5 Sensors

Replacement of sensors, for example:

  • Proximity switches
  • Safety sensors
  • Melt pressure and temperature sensors
  • Bearing and housing temperature sensors

Advantages: Technological advances, improved reliability and spare part availability.

6 Actuators

Inspection, maintenance or replacement of all actuating equipment. For example:

  • Cylinders
  • Valves
  • Motors
  • Signal lamps

Advantages: Improved reliability, extended lifetime, improved spare part availability.

7 Decentral Control Cabinet

Set-up of a decentral control cabinet (according to machine view on the back side) with new components, for example:

  • Decentral PLC system
  • Connecting terminals

Advantages: Compliance to current safety standards, technological advances, latest industrial standards, improved appearance, spare part availability.

8 Machine Cabling

  • Replacement of all power and control cables
  • Renewal of protective hoses and fittings

Advantages: High-quality insulation, latest cabling for industrial environments, reduction of problems caused due to defect wires, optimized work safety.

9 Machine Enhancement

General enhancement of the machine:

  • Disassembly of the machine, cleaning and repainting of single parts and reassembly

Advantages: Improved appearance of the machine, easy cleaning.

  • Function and damage check of all mechanical components of infeed, process unit and extrusion head, especially the critical spare/wear parts

Advantages: Optimization of process stability, increase of machine availability and reduction of maintenance costs e.g. due to early prevention of damage to rolls, screws, rotors, bearings, driving units etc.

10 Temperature Control Units and Piping

Refurbishment of temperature control units:

  • Function check of the complete water flow system including the TCU components (valves, hoses, filters, seals etc.), replacement if necessary
  • Rinsing and descaling of all heating/cooling circuits within the process units

Advantages: Maintenance of original temperature control functions, increase in process stability due to correct heating/cooling of the parts which are in contact with the product.

11 Driving Units

Refurbishment of drive units:

  • Function check of gears and motors, oil change for gears, inspection of single components (seals, bearings etc.) replacement if necessary

Advantages: Prevention of machine breakdowns/downtimes, maintenance of correct gear function, prevention of damage due to foreign particles.

12 Hydraulics

Refurbishment of hydraulics:

  • Cleaning of hydraulic system, oil change, hydraulic components (valves, hoses, seals etc.) are checked and replaced if necessary

Advantages: guarantee of hydraulic function, minimization of risk of leakage.